Polyphase junction box



Dec. 22, 1970 G. w. LEcocQ POLYPHASE JUNCTION BOX Filed Aug. 14, 1968Gera/d W. Lecocq Pfl/ IN VIL'N'I'OK.

United States Patent O 3,550,063 POLYPHASE JUNCTION BOX Gerald W.Lecocq, West Frankfort, Ill., assignor of onefourth each to Pleasant E.Smith, Carbondale, James A. Ozbourn, Carterville, and Thomas A. Miller,Marion,

Ill.

Filed Aug. 14, 1968, Ser. No. 752,680 Int. Cl. H01r 23/00, 13/16 U.S.Cl. 339-22 1 Claim ABSTRACT OF THE DISCLOSURE A number of parallelspaced bus -bars are embedded within a block of dielectric material.Each bus bar includes tapped bores therein at spaced intervals along itslength. Each tapped bore is aligned with a stepped diameter opening inthe dielectric block. A number of threaded modular connectors may beconductively engaged by the bus bars, the connectors being so shaped tocreate a weather seal with the block within the openings.

The present invention relates to connecting boards and more particularlyto a connecting board adapted to permit the attachment of modularconnectors thereto.

yConventional forms of connecting boards or junction boxes include anumber of receptacles or sockets therein. Mating plugs connected tocables are then inserted within an appropriate receptacle to complete acircuit from the receptacle to the cable. In certain devices, a bus baris disposed in proximity to the receptacles and wires are connectedbetween the bus bar and receptacle. However, such constructions arelimited in flexibility because they require the insertion of oneparticular xed type of receptacle in the junction box. Further, suchdevices are not adapted to withstand the elements of weather. Becausethe deterioration or burning out of a particular receptacle requires thedismantling of the connecting board, maintenance of such devices becomescostly and time-consuming.

The present invention includes a junction box having modular connectorsthreadably inserted through the casing of the junction box and into athreaded bore in an embedded bus "bar, A stepped diameter recess isformed in the casing of the junction box to communicate with thethreaded bore in the bus bar. Also, the modular con# nector has amatching surface to mate with the casing recess so that when the twobecome engaged, a weather seal is created. Further, the connectors ofthe present invention are removable from the bus bar so that if itbecomes necessary to replace the same, the connector may be simplyunscrewed and replaced by another. The present junction box permits theinsertion of male and female connectors, thus permitting installationilexibility. For example, one particular bus bar within the junction boxmay serve as a source of several tap-offs from a particular power phase.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part hereof, whereinlike numerals refer to like parts throughout, and in which:

FIG. 1 is a perspective view illustrating the present junction lbox withvarious connectors attached thereto.

FIG. 2 is a vertical crosssectional view taken along a plane passingthrough section line 2-2 of FIG. 1.

FIG. 3 is a transverse cross-sectional view taken along a plane passingthrough section line 3-3 of FIG. 1.

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FIG. 4 is a partial vertical sectional view taken along a plane passingthrough section line 4-4 of FIG. 1.

FIG. 5 is a partially cut away view of a cable rst terminal.

FIG. 6 is a partial sectional view taken along a plane passing throughsection line 4-4 of FIG. 6 illustrating a seated rubber plug.

FIG. 7 is a transverse cross-sectional view taken along a plane passingthrough section line 7 7 of FIG. 6.

FIG. 8 is a cross-sectional view illustrating the interior elements of amale connector.

Referring specifically to the drawings and more particularly to FIGS. 1and 2 thereof, the present junction box is denoted by reference numeral10 and includes a main block portion 12 fabricated from neoprene or thelike. The block includes a front panel surface 14, a rearward surface16, elongated lateral sides 18 extending along the length of the blockand transverse ends 20 and 22 disposed perpendicular to the lateralsides 18. The particular illustrated junction box includes fourelongated parallel spaced bus bars 24 embedded within block 12 andextending at the ends thereof between ends 20 and 22. FIG. 1 illustratesby way of example four cables 26 extending from the end 20.

As seen in FIG. 2 each cable 26 includes a first end termination with acentrally disposed conductor wire 28 extending inwardly from the end 20within a bore 30 formed inwardly from the bus bar edge at the end 20.Setscrews 32 are disposed within each bus bar 24 so as to secure eachconductor wire 28 within its associated bore 30. Instead of Setscrewswire 28 may be crimped within bore 30 by methods Well known in the art.During the manufacturing process, the conductor wire is secured withinthe bus bar and subsequently the dielectric casing is moldedtherearound. Further, a conical enlargement 33 is molded around theinsulation of each cable 26 adjacent end 20.

The opposite transverse end 22 includes four spaced, recesses 3'6, eachrecess forming a passage from end 22 to an adjacent edge of a bus bar24. As clearly shown in FIG. 2, each of these recesses includes a rstoutwardly communicating cylindrical portion extending to an inwardlytapered frustoconical portion which in turn extends inwardly to a secondcylindrical portion having a diameter smaller than that of the outwardcylindrical portion. Threaded bores 34 are formed within each bus barinwardly from the base of each recess 36. A modular, threaded connector,one type being denoted by 38 is inserted within each of the recesses forsecurement within threaded bore 34. Thus, as seen in FIG. 2, verticalalignment is maintained between each cable 26, associated conductor bar24 and connector 38.

'Considering conductor 38 in detail, a threaded stem 40 integrallymounts an elongated split sleeve tubular portion 46. As shown in FIG. 7,this sleeve is split along three lines to approximately one half thelength of the tubular portion. Three concentrically positioned retainingrings 48 engage the circumference of the tubular portion so that it isnormally urged to a contracted condition. A neoprene jacket or sleeve 42is molded around the tubular portion 46. As will be noted, the neoprenejacket end portion 44 adjacent the threaded stem 40` in- .Cludes asurface contour to conform with the recess 36 so that when connector 38is threadably inserted within threaded bore 34, a weather seal iscreated at the interface between recess 36 and mating jacket portion 44.The opposite end of the neoprene jacket includes an inwardly taperingrecess 49.

As will be observed from FIG. l, a male type modular connector denotedby 52 may be inserted, at will, in place of the female type connector38. Attention is directed to FIG. 8 which specifically shows theconstruction of the male type connector 52 including a threaded stern54, an intermediate cylindrical section 56 integrally attached to stem54, and a cylindrical prong or tip 58 coaxially disposed withintermediate section 56 and extending in a direction opposite threadedstern 54. A neoprene jacket or sleeve 60 covers the intermediate section56 and a portion of the tip 58. The jacket end portion adjacent thethreaded stern 54 has a configuration identical to that of jacketportion 36 of connector 38. An end surface portion 59 on the jacket 60mates with the tapering recess 49 in connector 38. Longitudinal ribelements 62 are formed around the circumference of each connector jacket60 as more clearly shown in FIG. 1 to facilitate manipulation of theconnector.

Instead of the permanently attached cables 26 shown in FIG. 1, side 20of block 12 may include recesses 36 such as are formed in side 22. Thiswould permit the insertion of a modular cable termination 52', shown inFIG. 5, within the recesses for electrical contact with the conductorbars 24. This termination is in effect similar to the previouslydiscussed connectors 52 but has one end of a respective cable 26' moldedthereto. Specifically, the cable termination includes a threaded stem 54and recess mating end portion 66. As will be noted, the cabletermination shown in FIG. illustrates an optional sealing member orannular projection 64 disposed in outward spaced relation to the endportion 66- so that a superior seal is formed.

In addition to connectors and cables attached along the block ends and22, a plurality of connection points are provided on the front surface14 of the dielectric block 12. Referring to FIG. 1, it will be seen thata typical example of the present invention includes four such equallyspaced connecting locations 68 arranged in a column along the length ofa particular bus bar 24. In the present embodiment, a three phase systemis contemplated so that an individual column of connecting locations areincluded for each phase of power. A fourth column is also included forground connections and is associated with a fourth bus bar. As seen inFIGS. 2 and 3, each connecting location 68 includes an inwardly boredrecess having a crosssection similar to that of aperture 36 shown inFIG. 2 as previously discussed. The outward end of the aperture at 68communicates with the forward face or surface 14 and the inward endcommunicates directly with the confronting surface of an associated busbar 24. A threaded bore 70 is formed coaxially inwardly of conductor bar24 and in spaced coaxial communicating relationship with aperture 68.Thus, any one of the threaded connectors 38, 52 and 52 aforementionedmay be threadably inserted Within a recess for electrical connectionwith an associated threaded bore 70 as shown in FIG. l.

In order to distinguish each phase column of the junction box, raisedindicators are utilized. For example, a first column is designated asground by the inclusion of a raised tab 72 having appropriate indiciaembossed or printed thereon. A second column is designated as the firstphase column by the inclusion of a single raised button 74. Likewise,two raised buttons 76 are employed adjacent the third column todesignate the second phase connection column and finally, three raisedbuttons 78 are employed to designate the third phase connection column.Four metal tubular inserts 80 are embedded within the central portion ofblock 12 and extend outwardly of the forward and rearward faces of theblock to permit the passage of fasteners 82 therethrough as shown bydotted line in FIG. 2 to mount the junction box 10 on a wall surface.

FIGS. 1 and 4 illustrate a plug member 84 having a fore-shortened sleeveor jacket portion with raised ribs cylindrically arranged thereon. Athreaded stem extends outwardly from the jacket or sleeve portion froman end portion which includes the previously discussed surfaceconfiguration mating with recesses 36 or 68. Thus, when a particularconnection point is not to be utilized, plug 4 member 84 is screwedtherein to keep the connection point weather sealed. A second type ofplug 86, clearly shown in FIG. 6, is inserted within a connection pointor recess 68 when that particular connection point is not -to be usedfor a protracted period of time. This plug includes a threaded sternportion 88 fabricated from neoprene or the like. A foreshortenedcylindrical head portion of the plug is integrally attached to thethreaded stern portion and when screwed within a recess 68, a flush litis effectuated. In order to permit removal of the plug at a later time,a recessed slot 90 is formed within the plug head.

Connection points have not been shown within the rearward face orsurface 16. But as will be appreciated, a connection array of phasecolumns resembling that shown in FIG, 1 or a single transverse row ofrecesses may be included in this rearward side if so desired. Theserecesses are adapted to receive threaded connectors S2' shown in FIG. 5.It will also be appreciated that connector blocks with mating connectorsof different sizes and numbers may be fabricated in accordance with thisinvention for different purposes and installations.

The foregoing is considered as illustrative only of the principles ofthe invention. Further, since numerous modiiications and changes willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation shown anddescribed, and accordingly all suitable modifications and equivalentsmay be resorted to, falling within the scope of the invention asclaimed.

What is claimed as new is as follows:

1. A connecting board compriising an insulating block, at least one busbar embedded in the block, a plurality of step-down recesses formed inthe face and a first transverse end of the block, the recessescommunicating with threaded bores in the bus bars; a cable integrallysecured at one end to an oppositely disposed transverse end of theblock, a conductor in the cable extending inwardly for internalconnection with the bus bar; a connector member for insertion in arecess, the member having an insulative sleeve with an end thereofshaped to conform with the recesses to form a weather-seal therewith, athreaded shank axially secured in the sleeve and extending outwardlyfrom an opposite sleeve end for threaded insertion in a recess, theconnector member further having a conductive portion arranged for quickdetachable engagement connected to the shank and extending from theWeather-seal end; raised projections formed on the block base toidentify the phase relation of power in the bus bar; a first threadedrecess sealing plug for flush insertion in the block base; a secondthreaded recess sealing plug having an outwardly extending knurled knobfor facilitating insertion and removal in a recess; and mounting holesformed in the block to receive fasteners for securing the flat blockback to a mounting surface.

References Cited UNITED STATES PATENTS 1,943,692 1/1934 Noyes 317-112X2,083,379 6/1937 Hill 317-103 2,613,287 10/1952 Geiger 339-18(C)X2,942,157 6/1960 Davis 317-119 3,210,720 10/1965 Harris, Jr. 339-1493,258,730 6/1966 Husband et al. 339-18(C) 3,325,765 6/1967 Hart et al339-259X FOREIGN PATENTS 540,268 4/1922 France 339-18(C) 894,781 4/1962Great Britain 339-22(B) MARVIN A, CHAMPION, Primary Examiner P. A.CLIFFORD, Assistant Examiner U.S. Cl. X.R.

